KTM 400/640LC4-E6 - Manuals

Page 3 - ENGLISH; IMPORTANT; WARNING; Chassis number; T A M P E R I N G W I T H N O I S E C O N T R O L S Y S T E M P R O H I B I T E D; CONSUMER INFORMATION FOR AUSTRALIA ONLY

ENGLISH 2 IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ...

Page 4 - Introduction; Chassis and Engine” of this manual.

ENGLISH 3 Introduction We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that guarantees tobring you lots of fun and enjoyment, provided that you clean and maintain itappropriately. Before you go for your first ride,...

Page 5 - INDEX

ENGLISH 4 Page SERIAL NUMBER LOCATIONS .............................................4 Chassis number ................................................................4 Engine number, engine type .............................................4 OPERATION INSTRUMENTS ........................................

Page 6 - Hand decompression lever; CAUTION; SERIAL NUMBER LOCATIONS

ENGLISH 5 Chassis number The chassis number is stamped on the right side of the steering head tube.Write this number into the relevant area on page 1. Engine number, engine type The engine number and engine type are stamped on the right hand side ofthe engine below the chain sprocket. Write this num...

Page 7 - Choke lever; Hand brake lever; Speedometer, indicator lamps; Ignition lock with 4 switch positions

ENGLISH 6 Choke lever If the choke lever 1 is pulled backwards, a bore will be opened in the carburetor through which the engine may draw in additional fuel. This produces a „rich“ fuel/air mixture necessary for cold start. If the choke leveris pushed forward up to the stop, the bore will be closed ...

Page 8 - Combination switch; Filler cap

ENGLISH 7 Combination switch The rocker switch LIGHTS 1 actuates the high beam or low beam. = High-beam light = Low-beam light The indicator switch 2 returns to central position after actuation. Press flasher switch towards switch housing to switch off the flasher. The horn is sounded with button 3 ...

Page 9 - Fuel tap; OFF In this position the fuel tap is closed. No fuel may flow to the; Shift lever; Foot brake pedal; OFF

ENGLISH 8 Fuel tap OFF In this position the fuel tap is closed. No fuel may flow to the carburetor. ON When using the motorcycle, the twist grip must be set to the ON position. Now fuel may flow to carburetor. In this position the tankempties down to the fuel reserve of approx. 2.5 liters. RES The r...

Page 10 - Compression damping of fork; Rebound damping of shock absorber; Baggage carrier

ENGLISH 9 2 2 1 1 3 4 Compression damping of fork The compression damping is to be set at the lower end of the fork tubes. Itonly regulates the degree of damping during compression.By using the knob 1 (COM), the degree of damping of the compression can be adjusted. Turn the knob clockwise to increas...

Page 11 - Running in the LC4-E models; Instructions for initial operation; DRIVING INSTRUCTIONS

ENGLISH 10 – Adjust the hand brake lever and the foot brake pedal to the most comfortable positions for you. – Get used to handling the motorcycle on an empty car park, before starting on a longer drive. Also try to drive as slowlyas possible and in standing position, to improve your feelingfor the ...

Page 12 - Starting when the engine is cold; Starting when the engine is warm or hot

ENGLISH 11 ENGLISH 11 Starting when the engine is cold 1 Open the fuel tap 1 2 Switch on ignition (turn ignition key 2 into position ). 3 Switch on emergency OFF switch 3 (symbol must be visible). 4 Switch transmission to idle (green indicator lamp N 4 lights up). 5 Operate cold starting device (cho...

Page 13 - Starting off; Braking; Stopping and parking

ENGLISH 12 Starting off Pull the clutch lever. Put the engine into first gear, slowlyrelease the clutch lever and open throttle at the same time. WARNING – B EFORE YOU START OFF , CHECK THAT THE MAIN STAND HAS BEEN SWUNG UP FULLY . I F THE STAND DRAGS ON THE GROUND , THE MOTORCYCLE CAN GO OUT OF CON...

Page 16 - PERIODIC MAINTENANCE SCHEDULE; A washed motorcycle can be checked more quickly which saves money!

ENGLISH 15 PERIODIC MAINTENANCE SCHEDULE 1. Service after 1000 km 2. Service after5000 km, then every 5000 km or once a year IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! S ERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM . M AINTENANCE WOR...

Page 18 - Tool set; MAINTENANCE WORK ON CHASSIS AND ENGINE

ENGLISH 17 WARNING ALL SERVICING AND ADJUSTMENT PROCEDURES DESIGNATED BY AN ASTERISK * REQUIRE THE KNOWLEDGEAND SKILLS OF A PROFESSIONAL. IN THE INTEREST OF YOUR OWN SAFETY, HAVE THESE PROCEDURES CARRIEDOUT AT A KTM SERVICE STATION! AT KTM YOUR MOTORCYCLE WILL RECEIVE OPTIMAL SERVICING BY SPECI-ALLY...

Page 19 - Checking and adjusting steering head bearing *; Changing the spring preload of the shock absorber

ENGLISH 18 Checking and adjusting steering head bearing * Check steering head bearing for play periodicaly. To check this putmotorcycle on a stand so that the front wheel is off the ground. Now try tomove the fork forward and backward. To adjust, loosen the five clamp screws 1 of the top triple clam...

Page 20 - Checking rubber ring on the WP rear shock absorber; Checking chain tension; Correct chain tension; Chain maintenance

ENGLISH 19 Checking rubber ring on the WP rear shock absorber A rubber ring mounted on the rear shock absorber serves as a vibrationdamper. This ring gets pressed together with time and loses its shock absorbing quality. Measure the distance between the two discs at various points around theircircum...

Page 21 - Chain wear; Adjusting of free travel at the hand brake lever; DOT

ENGLISH 20 Chain wear In order to check the chain wear, regard the following instructions:Shift the gear into idling and pull the upper chain strand with approx. 10-15kilogramm (33 lb) upwards (see figure). Now one can measure a space of18 chain reels at the lower chain strand. The chain should be r...

Page 22 - Checking of brake fluid level - front brake; Refilling the front brake fluid reservoir*; Checking the front brake pads; Changing the basic position of the foot brake pedal*

ENGLISH 21 Checking of brake fluid level - front brake The brake fluid reservoir is linked with the hand brake cylinder at the handlebar and the reservoir is provided with an inspection glass. With thereservoir in a horizontal position, the brake fluid level should not go belowmiddle of the glass. W...

Page 23 - Checking rear brake fluid level; Refilling the rear brake fluid reservoir*; Checking the rear brake pads

ENGLISH 22 Checking rear brake fluid level The reservoir for the rear disc brake is located on the left-hand side of thevehicle next to the carburetor carburetor connection boot. The brake fluidlevel may not drop below the „MlN” marking when the vehicle is in anupright position. WARNING I F THE BRAK...

Page 24 - Dismounting and mounting the front wheel (Supermoto)

ENGLISH 23 Dismounting and mounting the front wheel (400/640 LC4-E) To remove the front wheel, jack the motorcycle up on its frame so that thefront wheel no longer touches the ground.Loosen both clamp screws 2 on the left fork leg. Then loosen the collar nuts 1 before loosening the clamp screws 2 on...

Page 25 - Dismounting and mounting the rear wheel*; Checking the shock absorption rubbers in the rear hub*

ENGLISH 24 Dismounting and mounting the rear wheel* Park the motorcycle on the center stand. The rear wheel must not touch theground.Loosen the collar nut 1 , remove chain tensioner 2 , hold the rear wheel and pull out the wheel spindle 3 until the rear wheel is free but the brake caliper support is...

Page 26 - front; T I R E S - A I R P R E S S U R E; Checking spoke tension

ENGLISH 25 400/640 LC4-E front rear Road, driver only 1,8 bar (26psi) 2,0 bar (29psi) Road, with passenger 2,0 bar (29 psi) 2,2 bar (31psi) 640 Supermoto front rear Road, driver only 2,0 bar (29psi) 2,2 bar (31psi) Road, with passenger 2,2 bar (31psi) 2,4 bar (34psi) T I R E S - A I R P R E S S U R ...

Page 27 - Battery; Charging the battery; VOLT

ENGLISH 26 Battery The battery is mounted under the seat (remove the seat, see page 16)The battery has a closed system and therefore requires no maintenance. It isnot necessary to check the electrolyte level or to refill water. Simply keepthe battery poles clean and slightly grease them with an acid...

Page 28 - Main fuse; Fuses for individual power-consuming units; Exchanging the headlight lamp; Replacing the parking-light bulb; bk

ENGLISH 27 Main fuse Located near the battery under the seat, the main fuse 1 protects all power consumers.Replace a blown fuse only with an equivalent one. If a new fuse that hasjust been set in gets blown again, you are strongly advised to have it inspected by a KTM dealer.The fuse capacity is 20 ...

Page 29 - Exchanging the brake light and tail light bulb

ENGLISH 28 Exchanging the brake light and tail light bulb Remove the cap 1 on the underside of the license plate retainer. Turn the lamp socket 2 approximately 30° counterclockwise and pull it out of the tail light housing.Slightly depress the bulb, turn it approx. 30° counterclockwise and pull itou...

Page 30 - Checking the cooling liquid level

ENGLISH 29 Checking the cooling liquid level The cooling liquid should be 10 mm (0,4 in) above the cooling elementswhen the engine is cold (cf. diagram). In the event of the cooling liquidbeing drained, always fill the system before hand, then top off while theengine is running. WARNING I F POSSIBLE...

Page 32 - Adjusting the choke cable*; Adjusting the clutch cable; Engine oil; Checking engine oil level; MAX; TEMPERATUR

ENGLISH 31 Adjusting the choke cable* At the choke cable, there must always exist a play of approx. 2 mm (0.1 in).To check this, push choke lever fully forward and pull protective cover 1 from the adjuster piece 2 . Now, it must be possible to lift the outer covering of the cable by approx. 2 mm fro...

Page 33 - Oil circuit

ENGLISH 32 Oil circuit The oil pump 1 pumps the motor oil past the bypass valve 2 and through the oil filter 3 . Beyond the oil filter, one of the oil lines forks off to a jet 4 that injects motor oil to the piston pin bearing and the piston head. Thesecond oil line leads the main oil flow to the fr...

Page 34 - Changing oil filter *

ENGLISH 33 To facilitate bleeding of the oil system, we have added a hose connectionpiece and a plastic hose to the set of tools. Take an empty oil can (1 liter)and drill a 7 mm-diameter hole into the lid. Screw the hose connectionpiece into the lid from the outside, and secure it from the inside wi...

Page 35 - TROUBLE SHOOTING

ENGLISH 34 TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an erroroccur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error.We would like to point out that many op...

Page 38 - RE-INITIATION AFTER TIME OF STORAGE; CLEANING; CONSERVATION FOR WINTER OPERATION

ENGLISH 37 Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces.The best manner would be to use warm water that has been mixed with a normal trade washing detergent and a sponge. The harddirt can be removed before with the help of a soft water jet. ! CAUTION ! N EV...

Page 39 - White Power – Up Side Down 43; STANDARD ADJUSTMENT - FORK; SUPERMOTO

ENGLISH 38 TECHNICAL SPECIFICATIONS - CHASSIS 400/640 LC4-E, 640 LC4-E SUPERMOTO 2001 400 LC4-E 640 LC4-E 640 LC4-E Supermoto Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 Wheel travel front/rear 270 / 300 mm (10,6 / 11.8 in) Rear suspension Central shock absorber (WP) wit...

Page 40 - USA; BASIC CARBURETOR SETTING

ENGLISH 39 TECHNICAL DATA – ENGINE 400/640 LC4-E, 640 LC4-E SUPERMOTO 2001 Collar nut front axle M16x1,5, M17 40 Nm (30ft.lb) Collar nut rear axle M20x1,5 80 Nm (59ft.lb) Shock absorber top M10 45 Nm (33ft.lb) Shock absorber bottom M10 45 Nm (33ft.lb) Collar screws brake disk front M6 Loctite 243 + ...

Page 42 - CONSUMER INFORMA; STOPPING DIST; Model KTM; Light Load

ENGLISH 41 REPOR T ING SAFETY DEFECTS If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in adition to notifying KTM Sportmotorcycle USA, Inc. If NHTSA receiv...

Page 45 - HEAD WORD INDEX

ENGLISH 44 page Adjisting of free travel at the hand brake lever ....................19 Adjusting idling speed .........................................................28 Adjusting the choke cable ...................................................30 Adjusting the clutch cable .........................